Download High Precision Large Steel Structure Fabrication

Special Skills, Resources and Equipment
For more information contact:
SATCOM Technologies Wortham Steel Manufacturing
1004 N. MLK Avenue
Wortham, Texas 76693
Telephone: +1-254-765-3304
Fax: +1-254-765-3628
E-mail: [email protected]
Website: www.gdsatcom.com
SATCOM Technologies’ skill in producing welded
steel structures far surpasses the standards set
by the American Welding Society for structures
consisting of A36/A572 mild steel to the highly
sophisticated welding required for INVAR36
structures used in sophisticated scientific projects.
INVAR36, a nickel–iron alloy notable for its
uniquely low-coefficient of thermal expansion,
was used extensively in production of the radio
telescopes produced for the Atacama Large
Millimeter/submillimeter Array (ALMA). Wortham
is one of the few facilities throughout the world
equipped with the specialized welding equipment
and skill required to build with INVAR36.
SATCOM Technologies
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Computer-controlled plasma cutters transform steel
plate into complex shapes.
High Precision Large
Steel Structure Fabrication
Proven…Reliable….Precise…
• Over 40 years of experience
designing, manufacturing, and
installing large steel structures
Steel fabrication of today’s scientific structures
requires the highest precision in assembly –
sometimes to one one-thousandth of an inch.
• Supplier of choice for
government, military,
commercial and scientific
customers worldwide
The control techniques and metrology
instruments employed, such as Laser Trackers,
FARO Arm Coordinate Measuring Machines
and Leica Total Measurement Stations, ensure
that each project meets the most demanding
specifications.
• Highly precise to meet the most
exacting specifications
• Designed to meet the most
demanding tolerances
• Pre-assembly reduces cost, time
and field integration risks
Computerized plate
duplicators, beam line
machines and track
torches ensure the highest
accuracies in heavy steel
construction.
World-Class Facility
Located on 34 acres southeast of Dallas, Texas,
SATCOM Technologies’ Wortham heavy steel
fabrication facility boasts a 100,000 square foot
covered fabrication plant that is certified ISO14001 and OHSAS-18001 approved. With full
sandblast and paint capacity, 100 employees
and all appropriate security clearances needed,
General Dynamics’ SATCOM Technologies’ heavy
steel fabrication facility is ready to meet any
precision welded or bolted-together assignment.
High Precision Heavy Steel Fabrication
General Dynamics SATCOM
Technologies’ heavy
steel fabrication facility in
Wortham, Texas, delivers
the highest quality heavy
steel structures and systems
available today. Our proven
expertise allows us to
build large structures that
require the most exacting
specifications and highest
precision in assembly,
in some cases up to one
thousandth of an inch. Our
ASDE-X Tower, 150 Feet
ability to pre-assemble many
of the components for these structures allows us to
significantly reduce integration time in the field which,
in turn, significantly reduces risks and costs.
The combination of specialized equipment and skills in
producing large welded steel structures makes us one
of the few heavy steel fabricators in the world capable
of building with INVAR36 nickel-iron alloy. Through
the use of computerized control techniques and
metrology instruments such as Laser Trackers, FARO
Arm Coordinate Measuring
Machines and Leica Total
Measurement Stations we
can ensure that each project
meets the most demanding
specifications.
With more than 40 years
of experience designing,
manufacturing and installing
radar and telephony towers,
satellite earth stations, aircraft
rotator systems, and other
large precision-built scientific
installations, SATCOM
ASR-11 Tower 87 Feet
Technologies has become the
go-to choice for government, military, commercial and
scientific customers worldwide.
The computerized control techniques
and metrology instruments
employed ensure that each project
meets the most demanding
tolerances.
General Dynamics SATCOM
Technologies’ Wortham, Texas
facility is one of the few heavy
steel fabricators in the world
equipped with the specialized
welding equipment and skill
required to build with INVAR36
nickel-iron alloy.
Towers are a Specialty
SATCOM Technologies is one of the largest suppliers
of free-standing and self-support towers in the
world. The large steel towers measuring up to 150
feet tall, are installed at
hundreds of airports, cellular
telecommunications and
environmental monitoring
stations throughout the
United States and abroad.
Airport Safety
SATCOM Technologies
specializes in towers that
support Airport Surface
Detection Equipment
(ASDE-X) for runway safety.
In addition, SATCOM
NEON Environmental
Technologies produces
Observation Tower
Terminal Doppler Weather
Radar (TDWR), Digital Airport
Surveillance Radar (DASR) and Surface Movement
Radar (SMR) towers in a variety of configurations.
SATCOM Technologies has installed more than 50
major optical structures and radio astronomy platforms
worldwide ranging in antenna size from a mere three
meters in diameter to mammoth structures boasting
an 8,000 square-meter surface area and weighting
7,300 metric tons. Three of the five largest radio
telescopes operating today are supported by mounts,
subassemblies and control systems manufactured
by SATCOM Technologies’ Wortham steel fabrication
plant.
Major manufacturing and installation achievements:
The Green Bank Telescope
The Robert C. Byrd Green
Bank Telescope (GBT) is
the world’s largest fully
steerable radio telescope,
and at 450 feet tall (60%
taller than the Statue of
Liberty) and 16 million
pounds it is the world’s
largest moveable land
object. The GBT is part
of the national Radio
Astronomy Observatory
The Green Bank Telescope
site at Green Bank, West
Virginia.
The Sea-Based X-Band Radar (SBX-1) is a floating, selfpropelled, mobile, active electronically scanned array
early warning radar station designed to operate in midocean under conditions of high winds and heavy seas.
The SBX-1 is longer than a football field (381 feet) and
nearly twice as tall as the Roman Colosseum (279 feet
high). This self-propelled floating ‘stadium’ has many
Steel for Ecology
SATCOM Technologies is also providing more than 45
steel towers for the National Ecological Observatory
Network (NEON), managed by the National Science
Foundation to operate the first U.S. Continental-scale
scientific infrastructure for research, discovery and
education about ecological change. The towers are
used for monitoring and observing changes in the local
environment at all NEON field sites and ecosystems
across the U.S.
Signal Achievements
SATCOM Technologies’ towers, pedestals, and servo
units meet the precise tolerances, speed and durability
required to support and accurately position very large
radio telescope antennas, optical telescope mirrors and
their instruments operating in severe environmental
conditions year-after-year.
Many of today’s scientific structures
require the highest precision in
assembly – sometimes to one onethousandth of an inch.
Mobile User
Objective MUOS
System
Three 18.4-Meter
antennas mounted on
53-foot tall pedestals are
part of the U.S. Navy’s
Mobile User Objective
System (MUOS), the
U.S. Military’s next
generation narrowband,
global mobile satellite
communications
network. MUOS
provides U.S. armed
forces high reliability,
high quality telephonic
communication
services.
small radomes for various communications tasks and a
large central dome that encloses a phased-array, 1,800
ton (4,000,000 pound) X band radar antenna.
Atacama Large Millimeter/submillimeter
Array (ALMA) observatory in the Chilean Andes is
supported by 25 12-Meter antennas built by SATCOM
Technologies. The 115-ton, highly specialized radiotelescope antennas are operating 16,400 feet above sea
level to help astronomers study the origins of galaxies,
stars, and planets.
Discovery Channel Telescope
National Oceanic and Atmospheric
Administration (NOAA) GOES-R
SATCOM Technologies’ provided six 16-Meter
antennas for NOAA’s Wallops Command and Data
Acquisition Station in Wallops, VA. The antennas
support NOAA’s mission for weather forecasting,
severe storm tracking and meteorology research.
ALMA Antenna Array
The Discovery Channel Telescope (DCT) is a
4.3-meter aperture telescope funded by the Lowell
Observatory and The Discovery Channel. At 4.3-Meters,
the DCT is the fifth largest optical telescope in the
continental United States. The DCT is investigating a
wide and evolving range of research topics including
a survey of the composition of Kuiper Belt objects
orbiting the sun beyond Neptune; studies of the
physical properties of comets, investigations of the
evolution and structure of small galaxies and studies of
the masses of stars.
Sea-Based X-Band Radar
Sea-Based X-Band Radar
16 Meter GOES-R Antenna
MUOS 18.4 Meter Antennas
Aircraft Rotator Systems
Among SATCOM Technologies’ precision-weld
accomplishments are a number of Aircraft Rotator
Systems designed to support military aircraft during
radar cross section measurement testing. The
systems include Calibration Pylons and Hoist and
Wing Lift Systems to accurately turn and position the
aircraft during testing while remaining invisible to
radar signals. SATCOM Technologies has completed
a number of these Aircraft Rotator Systems for
government and commercial customers in the United
States, Asia and Europe.